Material and method for providing insulation and drainage to a foundation wall

ABSTRACT

A material and method for insulating and providing a drainage path for a foundation wall includes a non-woven thermoplastic board being for insulating and providing a drainage path for a foundation wall. The non-woven thermoplastic board has a thermal resistance of an R-value per inch thickness of at least 1. The non-woven thermoplastic board also has a vertical drainage ability per inch thickness of at least 135 Gallons/Hour/Lineal-Foot/inch at a pressure of 500 pounds per square foot (psf).

RELATED APPLICATIONS

This application claims the benefit of co-pending U.S. application Ser.No. 12/357,813 filed Jan. 22, 2009 which claims the benefit of U.S.Provisional Application Ser. No. 61/022,617 filed Dec. 22, 2009. Bothrelated applications, in their entireties, are incorporated herein byreference.

FIELD OF INVENTION

The instant application relates to a material and method for providinginsulation and drainage to a foundation wall.

BACKGROUND OF THE INVENTION

There is commonly known two types of foundations, shallow foundationsand deep foundations. Shallow foundations are usually embedded a meteror so into soil. One common type is the spread footing which consists ofstrips or pads of concrete (or other materials) which extend below thefrost line and transfer the weight from walls and columns to the soil orbedrock. Another common type of shallow foundation is the slab-on-gradefoundation where the weight of the building is transferred to the soilthrough a concrete slab placed at the surface. Deep foundations are usedto transfer a load from a structure through an upper weak layer of soilto a stronger deeper layer of soil. There are different types of deepfoundations including helical piles, impact driven piles, drilledshafts, caissons, piers, and earth stabilized columns. The namingconventions for different types of foundations vary between differentengineers. Historically, piles were wood, later steel, reinforcedconcrete, pre-tensioned concrete, and/or concrete masonry units.

Insulating the foundation building structures, like residential homesand commercial buildings, is important for many reasons. Insulation fora building's foundation wall can control the heat exchange between theground and the interior of the foundation wall, thus saving energy.Insulation can also provide a hydrostatic pressure barrier between thesurrounding earth and the foundation wall, thus providing structuraladvantages. Also, protecting the foundation wall from water saturationis important, especially below grade, or below ground, where dampnessand moisture is present year round. Thus, a material for insulating andproviding an adequate drainage path for a building's foundation wall isdesired.

One known product that may be used for insulating and providing adrainage path for a foundation wall is the use of fiberglass boards. Thefiberglass boards are applied against the foundation wall after awaterproof coating has been applied. The fiberglass boards can provide athermal resistance for insulating the foundation, they can providedrainage paths to prevent dampness and moisture from rotting thestructure, and they can provide a compression resistance to relieve thestructure from some of the hydrostatic pressure from the surroundingearth. However, all of the aforementioned properties could be improvedto provide an insulation and drainage material that provides betterthermal resistance, better drainage, and better compression resistance.

In addition to these desired improvements, the fiberglass boards arevery dangerous to manually install as the glass from the fiberglass canbe very irritating and damaging to the installer's skin. Also, thefiberglass boards are sensitive to sunlight, which means they willdegrade with any UV exposure. Thus, the fiberglass boards require thefoundation to be immediately back filled when installed. Moreover, thefiberglass boards are of a laminar structure with fibers running in thex and y planes, which does not provide for an ideal drainage path acrossthe boards. Also, the fiberglass boards do not stand up well to thechanging hydrostatic pressures when back filled, i.e., the fiberglassboard tends to break down or be crushed under the constantly changingpressure from the surrounding earth. Finally, the fiberglass boards arebonded with phenolic and formaldehyde resins, which are well known to bedangerous to the environment.

Another product that may be used for insulating and providing a drainagepath for a foundation wall is the use of dimpled plastic sheets. Likethe fiberglass boards, the dimpled plastic sheets are applied againstthe foundation wall. The dimpled plastic sheets can either be applieddirectly to the foundation wall or be applied after a waterproofmembrane. When applied after the waterproofing membrane, the dimplesface towards the soil with a filter fabric typically either glued orthermally bonded to the dimple side to keep the drainage area clear ofsoil particles. However the dimpled plastic sheet provides no thermalresistance. In addition, the dimpled plastic sheets can easily becrushed or damaged on the job site and are more difficult to install.Furthermore, when installing with a waterproof membrane, the membranemust be allowed to cure & dry for 24-36 hours before the dimple drainboard can be applied and secured, thus adding extra time and delay tothe building process. Another disadvantage to the dimpled plastic sheetsis that they need to be secured to the foundation wall by mechanicalfasteners, like nails, which have to puncture the waterproofingmembrane. Dimpled plastic sheets can also be secured by glues oradhesives, but these glues and adhesives are relatively expensive.

The instant invention is designed to provide an insulation and drainagematerial for a foundation that address all the problems mentioned above.

SUMMARY OF THE INVENTION

The instant invention includes a material and method for insulating andproviding drainage to a foundation wall. A material includes a non-woventhermoplastic board being for insulating and providing a drainage pathfor a foundation wall. The non-woven thermoplastic board has a thermalresistance of an R-value per inch thickness of at least 1. The non-woventhermoplastic board also has a vertical drainage ability per inchthickness of at least 135 Gallons/Hour/Lineal-Foot/inch at a pressure of500 pounds per square foot (psf).

BRIEF DESCRIPTION OF THE DRAWINGS

For the purpose of illustrating the invention, there is shown in thedrawings a form that is presently preferred; it being understood,however, that this invention is not limited to the precise arrangementsand instrumentalities shown.

FIG. 1 is a cross-sectional view of one embodiment of a foundationaccording to the instant invention.

FIG. 2 is a perspective view of the embodiment of the insulation anddrainage material shown in FIG. 1 provided in board form with a length(L) and a width (W).

FIG. 3 is a perspective view of the embodiment of the insulation anddrainage material shown in FIG. 1 provided in roll form with a width(W).

FIG. 4 is a cross-sectional view of another embodiment of a foundationwall according to the instant invention.

FIG. 5 is a cross-sectional view of another embodiment of a foundationwall according to the instant invention.

FIG. 6 is a cross-sectional view of another embodiment of a foundationwall according to the instant invention.

FIG. 7 is a cross-sectional view of another embodiment of a foundationwall according to the instant invention.

FIG. 8 is a cross-sectional view of another embodiment of a foundationwall according to the instant invention.

FIG. 9 is a cross-sectional view of another embodiment of a foundationwall according to the instant invention.

FIG. 10 is a perspective view of the embodiment of the insulation anddrainage material shown in FIGS. 4-7 provided in board form with alength (L) and a width (W).

FIG. 11 is a perspective view of the embodiment of the insulation anddrainage material shown in FIGS. 4-7 provided in roll form with a width(W).

FIG. 12 is a cross-sectional view of one embodiment of the insulationand drainage material manufactured according to the instant invention.

FIG. 13 is a diagram of one embodiment of the method of insulating andproviding a drainage path of a foundation wall according to the instantinvention.

DETAILED DESCRIPTION OF THE INVENTION

Referring to the drawings, wherein like numerals indicate like elements,there is shown in FIG. 1 an embodiment of an insulation and drainagematerial 10 for insulating and providing a drainage path for afoundation 8. The material 10 may be used for insulating and providing adrainage path for any structure, including, but not limited to, thefoundation of a residential or commercial building. The insulation anddrainage material 10 may be used for insulating and providing drainageto any portion of a building's structure, including, but not limited to,walls, roofs, foundations, retaining walls and/or surface drainage. Theinsulation and drainage material 10 may be a non-woven thermoplasticboard 14.

Non-woven thermoplastic board 14 may be used to insulate and provided adrainage path for the foundation 8, as shown in FIGS. 1, and 4-9.Non-woven thermoplastic board 14 may be any non-woven thermoplasticboard for insulating and providing a drainage path for foundation 8. Inone embodiment, non-woven thermoplastic board 14 may be a polyesterboard 14. For purposes of discussion, we may refer to non-woventhermoplastic board 14 as non-woven polyester board 14, however, theinstant invention is not so limited and may include any other boardswith thermoplastics.

Non-woven polyester board 14 may be used to insulate and provided adrainage path for the foundation 8, as shown in FIGS. 1 and 4-9.Non-woven polyester board 14 may be any non-woven polyester board forinsulating and providing a drainage path for foundation 8. Non-wovenpolyester board 14 may be utilized in any way to provide insulation anddrainage to foundation 8, including, but not limited to: being applieddirectly adjacent foundation wall 12 (not shown); being applied tofoundation wall 12 after a waterproofing membrane 34 is applied tofoundation wall 12 (see FIG. 1); being applied with a dimpled plasticsheet 32 after a waterproofing membrane 34 is applied to foundation wall12 (see FIG. 4); being applied with dimpled plastic sheet 32 after awaterproofing membrane 34 and a protective board 35 are attached tofoundation wall 12 (see FIG. 5); being applied with dimpled plasticsheet 32 directly against foundation wall 12 (see FIG. 6); being appliedwith dimpled plastic sheet 32 having a filtered fabric 33 appliedagainst waterproofing membrane 34 (see FIG. 7); being applied withdimpled plastic sheet 32 having filtered fabric 33 where material 10 isagainst waterproofing membrane 34 and the filtered fabric is adjacentthe soil or earth (see FIG. 8); and being applied against the dimples ofdimpled plastic sheet 32 which is applied against foundation wall 12with or without waterproof membrane 34 (see FIG. 9). Non-woven polyesterboard 14 may include any properties, including, but not limited to, athermal resistance, and a vertical drainage ability.

Non-woven polyester board 14 may be provided in any shape or form. Inone embodiment, non-woven polyester board 14 may be provided with athickness 30. Thickness 30 may be any thickness, including, but notlimited to between ¼ an inch and 10 inches. For example, thickness 30may be ¾ inch, 1 and ⅛ inch, 1 and 3/16 inch, 2 and ¼ inch, 2 and ¾inch, or 2 and ⅜ inch. In another embodiment, non-woven polyester boardmay be provided in a board form 26 with a length (L) and a width (W).See FIGS. 2 and 10. The board form 26 may include, but is not limited toa 4 foot by 3 foot (4×3) board, a 4 foot by 4 foot (4×4) board, and/or a4 foot by 8 foot (4×8) board. The board form 26 may allow the material10 to be treated as plywood for easier and more efficient installation,storage, delivery, etc. In yet another embodiment, non-woven polyesterboard may be provided in a roll form 28 (see FIGS. 3 and 11). Roll form28 may include any width, including, but not limited to, a 4 foot wideroll. The roll form 28 may allow the material to be rolled up aftermanufacturing, and then unrolled at the job site for application. Rollform 28 may allow easier and more efficient installation, storage,deliver, etc. of material 10.

The thermal resistance of material 10 may be for providing the adequateinsulation for foundation wall 12 to control the heat exchange betweenthe ground and the interior of the foundation wall, thus saving energy.The thermal resistance of material 10 may be any thermal resistance,including but not limited to, having an R-value of greater than 1 asmeasured by ASTM Test Number C-518. For example, the thermal resistanceof material 10 may be: an R-value of 2.5 for a ⅝ inch thick material 10;an R-value of 3 for a ¾ inch thick material 10; an R-value of 5 for a 1⅜inch thick material; and an R-value of 10 for a 2¾ inch thick material10. Thus, the R-value per inch thickness of material 10 may be atleast 1. In one embodiment, the R-Value per inch thickness of material10 may be at least 2. In another embodiment, the R-value per inchthickness of material 10 may be at least 3.

The vertical drainage ability of material 10 may be for providing theadequate vertical drainage for foundation wall 12. Providing adequatedrainage to foundation wall 12 may protect foundation wall 12 from watersaturation, which is especially important below grade, where dampnessand moisture may be present year round. The vertical drainage ability ofmaterial 10 may be any drainage ability, including, but not limited to,having a vertical drainage ability of greater than 100 Gallons/Hour/Footas measured by ASTM Test Number D-4716 at a pressure of 500 pounds persquare foot (psf). For example, the vertical drainage ability ofmaterial 10 may be: 113 Gallons/Hour/Lineal-Foot for a ⅝ inch thickmaterial at 500 psf; 225 Gallons/Hour/Foot for a 1⅜ inch thick materialat 500 psf; and 450 Gallons/Hour/Foot for a 2 and ¾ inch thick materialat 500 psf. Thus, in one embodiment of material 10, the verticaldrainage ability per inch thickness of material 10 inGallons/Hour/Lineal-Foot/inch may be at least 135 at 500 psf. In anotherembodiment of material 10, the vertical drainage ability per inchthickness of material 10 in Gallons/Hour/Lineal-Foot/inch may be atleast 160 at 500 psf. In yet another embodiment, the drainage abilityper inch thickness of material 10 in Gallons/Hour/Lineal-Foot/inch maybe at least 175 at 500 psf. In another example, the vertical drainageability of material 10 may be 60 Gallons/Hour/Foot for a 1.1 inch thickmaterial at 4000 psf. Thus, in one embodiment of material 10, thevertical drainage ability per inch thickness of material 10 inGallons/Hour/Lineal-Foot/inch may be at least 30 at 4000 psf. In anotherembodiment of material 10, the vertical drainage ability per inchthickness of material 10 in Gallons/Hour/Lineal-Foot/inch may be atleast 40 at 4000 psf. In yet another embodiment, the drainage abilityper inch thickness of material 10 in Gallons/Hour/Lineal-Foot/inch maybe at least 50 at 4000 psf.

The set of compression properties of material 10 may be for providingthe adequate compression properties to foundation wall 12. Thesecompression properties may provide a hydrostatic pressure barrierbetween the surrounding earth and the foundation wall, thus providingstructural advantages. The set of compression properties of material 10may be any set of compression properties. The compression properties ofmaterial 10 may allow material 10 to have higher vertical drainageability at greater depths or pressures from the surrounding earth orsoil. In addition, the compression properties of material 10 may allowmaterial 10 to continue to have higher vertical drainage ability aftermany cycles of pressure, for example, from the repeating freezing andthawing of the surrounding earth or soil.

A stiffening resin 24 may be included in one embodiment of insulationand drainage material 10, as shown in FIGS. 1 and 4-9. Stiffening resin24 may be any material applied to material 10 for stiffening orhardening material 10. For instance, stiffening resin 24 may be a resin,a film (extruded, melt-blown, etc.), a woven facer fabric, a non-wovenfacer fabric, etc. Stiffening or hardening material 10 may allow thematerial to be more easily installed as material 10 will act more as aboard and won't fold down while trying to be applied to foundation wall12. It is contemplated that insulation and drainage material 10 may bemade to any flexibleness by applying different amounts or types ofstiffening resin 24. In one embodiment, insulation and drainage materialmay be made very stiff (similar to a board) so that material 10 may beeasily installed on a flat foundation wall 12. In another embodiment,insulation and drainage material 10 may be very flexible which may allowmaterial 10 to be provided in roll form 28 and installed on a curvedfoundation wall 12, where material 10 will not crack like fiberglassboards. Stiffening resin 24 may be applied anytime, including, but notlimited to, during manufacturing of material 10 or any time thereafter.In one embodiment, as an alternative to stiffening resin 24, or incombination thereof, insulation and drainage material 10 may also bestiffened by hot rolling the outside of material 10. This hot rollingmay melt and bind the outside of material 10 to make it stiffer. Forinstance, if insulation and drainage material 10 is made withbicomponent fibers, hot rolling the outside of material 10 may melt andbind the bicomponent fibers towards the exterior of material 10, thus,making material 10 stiffer.

Non-woven polyester board 14 may be manufactured in any way to createinsulation and drainage material 10. The method of making material 10may further include the step of saturating the polyester board with astiffening resin 24. The method may also further include the step ofcutting the polyester board into a board form 26 or rolling thepolyester board into a roll form 28.

In one embodiment, non-woven polyester board 14 may be manufacturedwhere non-woven polyester board 14 may include an accordion shapedcross-section 22 (see FIG. 12). Manufacturing material 10 with accordionshaped cross-section 22 may provide the vertical drainage ability, setof compression properties, and thermal resistance for material 10.Accordion shaped cross-section 22 may include any length or widthaccordion shaped cross-section. The method of manufacturing material 10with the accordion shaped cross-section 22, also known as the verticallapping Process, may include the steps of: supplying staple fiber to acard(s); carding the web of polyester; and moving the web of polyesterinto a vertical lapping machine such as the commercial machine knows asStrudo. An insulation and drainage material 10 with an accordion shapedcross-section 22 is available from Structured Fibers Inc. of Satillo,Miss. as a product for use in automobiles as a foam replacement. Thismaterial may be modified in any way, for example, by adding stiffeningresin 24, in order to provide insulation and drainage material 10.

In another embodiment, non-woven polyester board 14 may be manufacturedby a carding and cross lapping process, where the polyester fibers maybe carded and cross lapped. In this carded and cross lapping process,non-woven polyester board 14 may be made by carding and cross lapping(90 degrees) a plurality of fibers including a binder (including, butnot limited to, low melt fibers, a thermal plastic powder, bicomponentfibers, chemicals and the like), plying the fibers to a certainthickness, and subsequently bonding the fibers and binders together.During the bonding process, the mat can be densified to a predetermineddensity using compression via equipment to include, but not limited to,a press, calender or double belt process.

In yet another embodiment, non-woven polyester board 14 may bemanufactured by a wet lay process. This wet lay process may include thesteps of: providing a wet lay web of polyester, which is then pleated,and finally sent into an oven for bonding into an accordion shape toform the non-woven polyester board. This method may provide non-wovenpolyester board 14 with accordion shaped cross-section 22.

In yet another embodiment, non-woven polyester board 14 may bemanufactured by a Spunbond process. This Spunbond process may includethe steps of: providing a Spunbond web of polyester, which is thenpleated, and finally sent into an oven for bonding into an accordionshape to form the non-woven polyester board 14. This method may providenon-woven polyester board 14 with accordion shaped cross-section 22.

In yet another embodiment, non-woven polyester board 14 may bemanufactured by a block process. In this block process, non-wovenpolyester board 14 may be a fibrous mat structure that may bemanufactured by opening and depositing a plurality of fibers, including,binders, into a large rectangular container (box) which can be heatedand have pressure applied from the top of the box. The fibers are heatedand pressed to the desired density and then cooled. The resulting blockcan then be skived like a block of foam into sheets of desired thicknessrepresenting different thermal insulating values.

In yet another embodiment, non-woven polyester board 14 may bemanufactured by an airlay process. This airlay process may include thesteps of: taking the fibers through a mechanical opening process, thenusing a large volume of air, transporting the fibers to a forming headwhich deposits a uniform layer of fiber on a moving conveyer belt. Theseopen fibers can then be pressed down to a certain thickness for thedesired thermal resistance using a machine like a double belt press.

In any embodiment of manufacturing non-woven polyester board 14,non-woven polyester board 14 may be manufactured by a laminate/compositeprocess. In this laminate/composite process, webs made by any nonwoven,woven or knitted process, may be laminated together to form material 10with specified thermal insulating and drainage values. One particularlyuseful construction incorporates variable porosity mats designed tominimize blinding of the drainage plane by silt infiltration.Additionally, incorporation of a very open material such as an entanglednet product in the interior of the composite construction can channelwater very quickly in the drainage plane. Another construction couldconsist of different materials laminated together, which could includean entangled net product, dimpled plastic sheet 32, and or bentonitepanels, laminated to material 10 with the entangled net product anddimple plastic sheet 32 on one side of material 10. In thisconstruction, the entangled net product and dimpled plastic sheet 32 maybe positioned next to the foundation wall 12.

Examples

The below table compares the vertical drainage ability and thermalresistance for various thicknesses of the prior art fiberglass boardscompared to the non-woven polyester board 14 made according to theinstant invention. The non-woven polyester board 14 was made accordingto the vertical lapping process described above. The vertical drainageability was measured according to ASTM Test Number D-4716 at a pressureof 500 pounds per square foot (psf). The thermal resistance was measuredaccording to ASTM Test Number C-518.

DRAINAGE ABILITY PER THERMAL THICKNESS RESISTANCE PER (Gallons/Hour/THERMAL THICKNESS THICKNESS DRAINAGE ABILITY Lineal- RESISTANCE (ft² ·hr · ° F./ MATERIAL (in) (Gallons/Hour/Foot) Foot/inch) (ft² · hr · °F./Btu) Btu/inch) Non-Woven ⅝ 113 180.8 2.5 4 Polyester Board Non-Woven¾ 135 180 3 4 Polyester Board Fiberglass ¾ 74 98.67 3.2 4.27 BoardNon-Woven 1 and ⅜ 225 163.64 5 3.64 Polyester Board Fiberglass 1 and3/16 118 99.37 5 4.21 Board Non-Woven 2 and ¾ 450 163.64 10 3.64Polyester Board Fiberglass 2 and ⅜ 237 99.79 10.1 4.25 Board

The below table shows the thermal resistance of ten differentthicknesses of non-woven polyester board 14 made according to theinstant invention. The thickness is measured in inches, and the thermalresistances were measured according to ASTM Test Number C-518.

THERMAL THERMAL RESISTANCE RESISTANCE PER INCH (Btu-in/ THERMALTHICKNESS THICKNESS Hr · ft² · ° F.) RESISTANCE (ft² · hr · ° F./ (in.)@ 72° F. (ft² · hr · ° F./Btu) Btu/inch) 1.09 0.3536 3.08 2.8 1.090.2489 4.37 4.0 1.17 0.2697 4.33 3.7 1.23 0.2572 4.76 3.9 1.24 0.24894.97 4.0 1.26 0.2441 5.15 4.1 1.27 0.2420 5.25 4.1 3.50 0.3044 11.50 3.33.30 0.4181 7.89 2.4

As can be seen from the above tables, non-woven polyester board 14 mayprovide a user friendly synthetic thermal resistant board that is agreat alternative to fiberglass boards. Non-woven polyester board 14 mayprovide better drainage than fiberglass and is also much more durable.In addition, non-woven polyester board 14 may be made without the use ofphenolic and formaldehyde resins, which makes material 10environmentally friendly. Non-woven polyester board 14 may also be madeout of recycled post consumer and industrial waste, thus providing evenmore environmental benefits. Furthermore, unlike fiberglass boards,non-woven polyester board 14 will not irritate or harm your skin and maybend easily, which makes it very easy to work with. Finally, non-wovenpolyester board 14 will not degrade when exposed to UV rays or sunlight,thus, non-woven polyester board 14 can be installed in foundation 8without needing to be immediately back filled, or it may be stored on ajob site without UV protection.

The insulation and drainage material 10 for a foundation wall may beused in the foundation 8 for a building. See FIGS. 1 and 4-9. Thefoundation 8 for a building may include: a foundation wall 12; awaterproofing membrane 34 applied to the foundation wall 12; and the newinsulation and drainage material 10 being adjacent to the waterproofingmembrane (see FIG. 1). The foundation may also include a drainage pipe36 and gravel 38 at the bottom of the foundation wall. The foundation 8may be insulated and provided with a drainage path via insulation anddrainage material 10.

The foundation wall 12 may be included in foundation 8. Foundation wall12 may be built in any size or shape. Foundation wall 12 may be a flatfoundation wall or may be curved. The foundation wall 12 may also bemade out of any material, including, but not limited to concrete.Foundation wall 12 may be a shallow or deep foundation wall.

Dimpled plastic sheet 32 may be optionally installed with insulation anddrainage material 10 in foundation 8. See FIGS. 4-11. Dimpled plasticsheet 32 may be for providing extra drainage to foundation wall 12.Dimpled plastic sheet 32 may also be for providing extra compressionproperties for foundation wall 12. Dimpled plastic sheet 32 may be anymaterial for providing extra drainage and/or extra compressionproperties for foundation wall 12. Dimpled plastic sheet 32 may beintegral with insulation and drainage material 10 (see FIGS. 10 and 11)or it may be provided and applied separately. Dimpled plastic sheet 32may be oriented in any manner, including, but not limited to, beingoriented where the dimples are protruding toward wall 12 and away frommaterial 10, where material 10 covers the holes on the back side ofdimpled plastic sheet 32. This orientation may prevent the dimples frompenetrating material 10. The dimpled plastic sheet 32 may be any type ofdimpled plastic sheet, including, but not limited to, a punched anddrawn material or an extruded (unto a dimpled calender roll) material.Example dimpled plastic sheets 32 are commercially available fromCosella Dorken of Beamsville, Ontrario in Canada, J-Drain of Alpharetta,Ga., and American Wick of Monroe, N.C.

In the embodiment shown in FIG. 4, dimpled plastic sheet 32 may beapplied between insulation and drainage material 10 and waterproofingmembrane 12 adjacent foundation wall 12. In this embodiment, theinsulation and drainage material 10 may optionally have the dimpledplastic sheet 32 adhered (via mechanical fasteners or adhesives orthermal bonding) to a surface thereof so that the open cups of thedimpled plastic sheets are closed by the material.

In the embodiment shown in FIG. 5, dimpled plastic sheet 32 may beapplied between insulation and drainage material 10 and protective board35 adjacent foundation wall 12. In this embodiment, the insulation anddrainage material 10 may optionally have the dimpled plastic sheet 32adhered (via mechanical fasteners or adhesives or thermal bonding) to asurface thereof so that the open cups of the dimpled plastic sheets areclosed by the material. The protective board 35 may prevent the dimplesof dimpled plastic sheet 32 from puncturing waterproofing membrane 34.

In the embodiment shown in FIG. 6, dimpled plastic sheet 32 may beapplied between insulation and drainage material 10 and foundation wall12 with the dimples facing foundation wall 12. In this embodiment, thedimples of dimpled plastic sheet 32 may be directly against foundationwall 12 with no waterproofing membrane. In this embodiment, theinsulation and drainage material 10 may optionally have the dimpledplastic sheet 32 adhered (via mechanical fasteners or adhesives orthermal bonding) to a surface thereof so that the open cups of thedimpled plastic sheets are closed by the material.

In the embodiment shown in FIG. 7, dimpled plastic sheet 32 may beapplied with filtered fabric 32 covering the dimples, where dimpledplastic sheet 32 is between insulation and drainage material 10 andwaterproofing membrane 12 adjacent foundation wall 12. Filtered fabric33 may prevent the dimples of dimpled plastic sheet 32 from puncturingwaterproofing membrane 34. In this embodiment, the insulation anddrainage material 10 may optionally have the dimpled plastic sheet 32adhered (via mechanical fasteners or adhesives or thermal bonding) to asurface thereof so that the open cups of the dimpled plastic sheets areclosed by the material.

In the embodiment shown in FIG. 8, dimpled plastic sheet 32 may beapplied with filtered fabric 32 covering the dimples, where dimpledplastic sheet 32 is adjacent insulation and drainage material 10 whichis applied against foundation wall with or without waterproofingmembrane 12. Filtered fabric 33 may prevent the soil from clogging thedrainage path of dimpled plastic sheet 32. In this embodiment, theinsulation and drainage material 10 may optionally have the dimpledplastic sheet 32 adhered (via mechanical fasteners or adhesives orthermal bonding) to a surface thereof so that the open cups of thedimpled plastic sheets are closed by the material.

In the embodiment shown in FIG. 9, dimpled plastic sheet 32 may beapplied with between insulation and drainage material 10 and foundationwall 12, with or without waterproofing membrane 34, where the dimplesface towards material 10.

Waterproofing membrane 34 may be optionally included in foundation 8 ofthe instant invention. See FIGS. 1, 4-5 and 7-9. Waterproofing membrane34 may be for waterproofing foundation wall 12. Waterproofing membrane34 may be any known material capable of waterproofing foundation wall12. Waterproofing membrane 34 may be made of any material, including,but not limited to, an asphalt.

Filtered fabric 33 may optionally be included in foundation 8 of theinstant invention. See FIGS. 7 and 8. Filtered fabric 33 may be forpreventing soil and the surrounding earth from entering and clogging thedrainage path of dimpled plastic sheet 32. Filtered fabric 33 may besecured to the dimples of dimpled plastic sheet 32. Filtered fabric 33may be any filtered fabric known in the art.

Protective board 35 may be optionally included in foundation 8 of theinstant invention. See FIG. 5. Protective board 35 may be for preventingdimpled plastic sheet 32 from penetrating waterproofing membrane 34.Without protective board 35, dimpled plastic sheet 32 may be forced topenetrate waterproofing membrane 34 (making the waterproofing membraneless waterproof), due to the changes in hydrostatic pressure from thesurrounding earth. Protective board 35 may be any device capable ofpreventing dimpled plastic sheet 32 from penetrating waterproof membrane34. Protective board 35 may be made of any material, including, but notlimited to, a foam.

Drainage pipe 36 may be included in foundation 8 of the instantinvention. See FIGS. 1, 4 and 5. Drainage pipe 36 may be for any knownuses in the art, including, providing a drainage pipe at the bottom offoundation wall 12. Drainage pipe 36 may be any type of drainage pipeknown in the art, including, but not limited to, a standard PVC drainagepipe or a strip drain.

Gravel 38 may be included in foundation 8 of the instant invention. SeeFIGS. 1, 4 and 5. Gravel 38 may be for any known uses in the art,including, preventing drainage pipe 36 from becoming clogged from thesurrounding soil. Gravel 38 may be any type of gravel known in the art.

As shown in FIG. 13, method 40 of the instant invention is forinsulating foundation 8 and providing a drainage path for foundation 8.Method 40 may include any steps for insulating foundation 8 andproviding a drainage path for foundation 8. In one embodiment, method 40may include the following steps: a step 42 of building foundation wall12; a step 44 of applying waterproofing membrane 34 to foundation wall12; and a step 46 of installing insulation and drainage material 10approximate to the exterior of foundation wall 12.

Step 42 of building foundation wall 12 may be included in method 40 ofinsulating foundation 8 and providing a drainage path for foundation 8.See FIG. 13. Step 42 may include any known steps in the art for buildingfoundation wall 12, including, but not limited to, pouring any type ofconcrete foundation wall.

Step 44 of applying waterproofing membrane 34 to foundation wall 12 maybe included in method 40 of insulating foundation 8 and providing adrainage path for foundation 8. See FIG. 13. Step 44 may include anyknown steps in the art for applying waterproofing membrane 34 tofoundation wall 12, including, but not limited to, applying a liquidasphalt waterproofing membrane, or self adhered membrane, ontofoundation wall 12.

Step 46 of installing insulation and drainage material 10 adjacent tothe exterior of foundation wall 12 may be included in method 40 ofinsulating foundation 8 and providing a drainage path for foundation 8.See FIG. 13. Step 46 may include any steps for installing material 10approximate to the exterior of foundation wall 12, including, but notlimited to, securing material 10 to the exterior of foundation wall 12via mechanical fasteners, adhesives or thermal bonding. Step 46 ofinstalling insulation and drainage material 10 approximate to theexterior of foundation wall 12 may be done at any time, including, butnot limited to, being done immediately after applying waterproofingmembrane 32. This means that insulation and drainage material 10 may besecured adjacent to waterproofing membrane 34 even when waterproofingmembrane 34 has not dried or is still wet. Step 46 may includeinstalling material 10 in any form, including, but not limited to, inboard form 26 (see FIGS. 2 and 10) or in roll form 28 (see FIGS. 3 and11). In one embodiment, step 46 may also include a step 48 of attachingdimpled plastic sheet 32 to insulation and drainage material 10 (seeFIGS. 4-8).

Step 48 of positioning dimpled plastic sheet 32 next to insulation anddrainage material 10 may be included in method 40 of insulatingfoundation 8 and providing a drainage path for foundation 8. See FIG.13. Step 48 may include any steps for positioning dimpled plastic sheet32 next to insulation and drainage material 10, including, but notlimited to, attaching dimpled plastic sheet 32 to material 10 viamechanical fasteners, adhesives or thermal bonding. Step 48 may be doneat any time, including, but not limited to, during the manufacture ofinsulation and drainage material 10, while insulation and drainagematerial 10 is being installed in foundation 8, or anytime therebetween. In one embodiment, step 48 may include positioning dimpledplastic sheet 32 next to insulation and drainage material 10, wheredimpled plastic sheet 32 is adjacent to waterproofing membrane 34. Inanother embodiment, step 48 may include positioning dimpled plasticsheet 32 next to insulation and drainage material 10, where dimpledplastic sheet 32 is adjacent to protective board 35, which may beadjacent to waterproofing membrane 34. In all of these two embodiments,as shown in FIGS. 4-8, step 48 may include positioning dimpled plasticsheet 34 next to material 10, where the dimples face away from material10. In the embodiment shown in FIG. 9, step 48 may include positioningdimpled plastic sheet 34 next to material 10, where the dimples facetowards material 10.

The instant invention may be embodied in other forms without departingfrom the spirit and the essential attributes thereof, and, accordingly,reference should be made to the appended claims, rather than to theforegoing specification, as indicated in the scope of the invention.

1. An insulation and drainage material for a foundation comprising: anon-woven thermoplastic board being for insulating and providing adrainage path for a foundation wall; said non-woven thermoplastic boardhaving a thermal resistance having an R-value per inch thickness of atleast 1; and said non-woven thermoplastic board having a verticaldrainage ability per inch thickness of at least 135Gallons/Hour/Lineal-Foot/inch at a pressure of 500 pounds per squarefoot (psf).
 2. The insulation and drainage material for a foundation ofclaim 1 where said non-woven thermoplastic board having a verticaldrainage ability per inch thickness of at least 160Gallons/Hour/Lineal-Foot/inch at a pressure of 500 pounds per squarefoot (psf).
 3. The insulation and drainage material for a foundation ofclaim 1 where said non-woven thermoplastic board having a verticaldrainage ability per inch thickness of at least 175Gallons/Hour/Lineal-Foot/inch at a pressure of 500 pounds per squarefoot (psf).
 4. The insulation and drainage material for a foundation ofclaim 1 where said non-woven thermoplastic board having a verticaldrainage ability per inch thickness of at least 30Gallons/Hour/Lineal-Foot/inch at a pressure of 4000 pounds per squarefoot (psf).
 5. The insulation and drainage material for a foundation ofclaim 1 where said non-woven thermoplastic board having a verticaldrainage ability per inch thickness of at least 40Gallons/Hour/Lineal-Foot/inch at a pressure of 4000 pounds per squarefoot (psf).
 6. The insulation and drainage material for a foundation ofclaim 1 where said non-woven thermoplastic board having a verticaldrainage ability per inch thickness of at least 50Gallons/Hour/Lineal-Foot/inch at a pressure of 4000 pounds per squarefoot (psf).
 7. The insulation and drainage material for a foundation ofclaim 1 where said non-woven thermoplastic board having a thermalresistance having an R-value per inch thickness of at least
 2. 8. Theinsulation and drainage material for a foundation of claim 1 where saidnon-woven thermoplastic board being a non-woven polyester board.
 9. Theinsulation and drainage material for a foundation of claim 1 furthercomprising a dimpled plastic sheet attached to said non-woventhermoplastic board.
 10. A method of insulating and providing a drainagepath for a foundation comprising the steps of: building a foundationwall; and installing an insulation and drainage material approximate tothe exterior of said foundation wall; said insulation and drainagematerial comprising a non-woven thermoplastic board having a thermalresistance having an R-value per inch thickness of at least 1, and avertical drainage ability per inch thickness of at least 135Gallons/Hour/Lineal-Foot/inch at a pressure of 500 pounds per squarefoot (psf).
 11. The method of insulating and providing a drainage pathfor a foundation of claim 10 further comprising the step of applying awaterproofing membrane to said foundation wall.
 12. The method ofinsulating and providing a drainage path for a foundation of claim 11where said step of installing said insulation and drainage materialbeing done immediately after said step of applying said waterproofingmembrane.
 13. The method of insulating and providing a drainage path fora foundation of claim 10 where said non-woven thermoplastic board beinginstalled in a board form being selected from the group consisting of: a4 foot by 3 foot board, a 4 foot by 4 foot board, and a 4 foot by 8 footboard.
 14. The method of insulating and providing a drainage path for afoundation of claim 10 where said non-woven thermoplastic board beinginstalled in a roll form.
 15. The method of insulating and providing adrainage path for a foundation of claim 10 further comprising the stepof positioning a dimpled plastic sheet next to said insulation anddrainage material.